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Specification 3SS-MAA0-00001 STANDARD SPECIFICATION FOR INDUCED DRAFT FANS (AXIAL) Bechtel Confidential  Bechtel

Specification 3SS-MAA0-00001

STANDARD SPECIFICATION

FOR

INDUCED DRAFT FANS (AXIAL)

Bechtel Confidential

Bechtel Corporation 2006, 2003. Contains confidential and/or proprietary information to Bechtel and its affiliated companies which shall not be used, disclosed, or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission. All rights reserved.

BECHTEL POWER CORPORATION FREDERICK, MARYLAND

NO.

DATE

 

REVISIONS

BY

CHK’D

APPROVALS

000

10/29/03

Incorporates PIP-Power-ENG-01-82. Issued for Use.

PNV

KRL

J. Olson

 

for PFN

001

5/15/06

Added 1.4.e & i, 2.2.5.h, 2.2.8.c, 2.2.9.c, 2.2.10, 2.2.14, 3.1.2.c, 3.2.4, 3.2.5, and 3.3.3. Revised 1.1.a, b, g, k, m, n & o; 1.2.e; 1.3.2. a & c; 1.4.c &

RV

PNV

J.Olson

 

for PFN

f;

1.7.1; 2.2; 2.2.1.a, b & c; 2.2.2.c, j, k & l; 2.2.5.a,

b, e & f; 2.2.6.a, d, e & f; 2.2.7.a & e; 2.2.8.a, b, d,

& f; 2.2.9.b & c; 2.2.11.c; 2.2.12.a; 2.4.2.c & f; 3.2.1; and 3.2.2.

e

Incorporated Lesson Learned 5111. Reissued for use.

Specification 3SS-MAA0-00001

TABLE OF CONTENTS

Page

1.0

GENERAL

1

1.1 Work Included

1

1.2 Related Work Not Included

2

1.3 Service Requirements

3

1.4 Terminal Points

3

1.5 Quality Assurance

4

1.6 Submittals

4

1.7 References

5

2.0

PRODUCTS

6

2.1 Materials

6

2.2 Design Requirements

7

2.3 Motor Drives

16

2.4 Noise Levels

16

2.5 Fabrication

17

3.0

EXECUTION

18

3.1 Inspection

18

3.2 Shop Testing

19

3.3 Shipping, Handling, and Storage

19

3.4 Acceptance Test

19

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Specification 3SS-MAA0-00001

STANDARD SPECIFICATION

FOR

INDUCED DRAFT FANS (AXIAL)

1.0 GENERAL

1.1 WORK INCLUDED

Design, furnish materials for, fabricate, test, and deliver variable-pitch, horizontal, axial- flow induced draft (ID) fans and electric motor drives with accessories in accordance with this specification. The following items and services shall be provided, as a minimum:

a. Fans, each including the following:

Inlet box with access doors and housing

Drive shaft

Hubs with airfoil blades

Flexible coupling with coupling guard

Water-cooled lube oil supply unit for bearing lubrication, with standby pump

Water-cooled control oil supply unit for blade control, with standby pump

Seal air units with ducting and heating elements, if applicable

Servomotor

Control drive and control drive linkage

Bearings, pedestals, and soleplates

Bearing thermocouples

Bearing vibration monitoring system

Diffuser with support steel to grade

Single-bladed outlet dampers, if required

Stall probes

Required instrumentation

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Specification 3SS-MAA0-00001

b. Outlet silencers, if required

c. Motor drives

d. Asbestos-free gaskets and bolting for flanged connections

e. One set of special tools required for erection, startup, and maintenance

f. Drawings and documentation

g. Shop priming and finish painting of uninsulated surfaces

h. Services of technical representative(s) for consultation during equipment erection, startup, and testing

i. Startup spare parts

j. Insulation clips

k. Supply of acoustical/thermal insulation system including design (type, material, and thickness), if required to meet the specified noise levels

l. Nondestructive examinations (NDEs) and shop tests per paragraphs 3.1.2 and 3.2 of this specification

m. Appropriate arrangement/provision to facilitate easy access to the rotating assembly for maintenance requirements

n. Antifriction (roller) and ball bearings or, as an alternate, sleeve bearings

o. Expansion joints at fan inlet and between the damper and duct at fan outlet

p. Lubrication and control oil piping system between the fan and lube unit

1.2 RELATED WORK NOT INCLUDED

The following related work is not included:

a. Unloading, handling, and storage at jobsite

b. Foundations and anchor bolts

c. Installation of fan, electric driver, and accessories

d. Motor controls and external wiring

e. Thermal insulation

f. Ductwork

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Specification 3SS-MAA0-00001

1.3 SERVICE REQUIREMENTS

1.3.1

Plant Location and Environmental Conditions

a.

Plant location and jobsite environmental conditions are provided in the Technical Specification for General Project Requirements (see parent material requisition [MR]).

b.

Cooling water will be made available by the Buyer as required for miscellaneous service requirements. Cooling water will be in accordance with the conditions listed in the parent MR.

c.

All supplied equipment will be located outside.

d.

The instrument air will be supplied by the Buyer in accordance with conditions listed in the parent MR.

e.

Available electrical power sources for the operation of the supplied equipment are as listed in the parent MR.

f.

Site elevation and ambient temperatures are as listed in the parent MR.

g.

Seismology and wind loading shall be in accordance with the parent MR.

1.3.2

Operating Conditions

a.

The fans will operate in conjunction with fossil-fuel-fired steam generators. The ID fans will be located in the flue gas system.

b.

The performance requirements are specified in the data sheets (see parent MR).

c.

Minimum continuous flow for the fans will be approximately 15 percent of the maximum continuous rating (MCR) condition specified in the parent MR, except for periods during steam generator startup and shutdown.

d.

Maximum tip-speed of the fan shall be 500 fps (152 m/s).

e.

Fuel, ash, and flue gas analyses will be provided in the parent MR.

f.

The ID fan shall be designed for cycling operations in accordance with the anticipated operational data summarized in the parent MR.

1.4 TERMINAL POINTS

The Seller’s supply shall terminate at the following points:

a. Seller’s flue gas inlet expansion joint on inlet box

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Specification 3SS-MAA0-00001

 

b.

Outlet flange of the expansion joint at the outlet damper or silencer, as applicable

c.

Motor terminals and enclosure – Main motor, turning gear motor (if required), outlet damper motor, lube oil skid, and control oil skid

d.

Fan bearing thermocouple with weatherproof head, motor bearing RTDs, and winding RTDs wired to a junction box on the motor. Wire motor space heater up to the junction box. If CTs have been provided for self-balancing relays, wire them up to the terminal box with shorting-type CT terminals.

e.

Local terminal box or other locations specified in the parent MR for locally mounted control devices such as valves, dampers, position switches, electronic instruments, stall probe pressure pick-ups

f.

Cooling water inlet and outlet connections for lube oil, control oil skids, and motors

g.

Diffuser and inlet box support steel at grade

h.

Bearing soleplate

i.

Instrument air connections

1.5

QUALITY ASSURANCE

1.5.1 The Seller shall have a Quality Management System (QMS) that complies with

the applicable requirements of ISO 9001:2000 or equivalent international or national standard (e.g., BS 5750 Part 2, EN 29002, and ANSI/ASQC Q9002).

1.5.2 The Buyer reserves the right to evaluate the Seller’s and its subsellers’ QMS

documentation and to decide if the systems meet the requirements of this project. The Buyer or its representatives also reserve the right to carry out appraisals and quality

audits of the Seller’s and its subsellers’ QMSs at any time during the period of the contract to verify compliance with and maintenance of the QMSs and contract requirements.

1.6 SUBMITTALS

1.6.1 General

Submit engineering documents in accordance with the document submittal requirements (see parent MR). Submittal of incomplete, unfinished, or unchecked documents will not be considered as meeting the document submittal schedule requirements. Only completed and checked documents with all requested data and information will be accepted as fulfilling the Seller’s obligation for each of the various document submittal schedule requirements.

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Specification 3SS-MAA0-00001

Submit drawings, data, and manuals to the Buyer in the English language and in other languages as specified in the parent MR and in accordance with the ANSI System of Measurement (foot-inch) or the International System of Units (SI), as defined in the parent MR. Express dimensions on drawings to the nearest 1/16 of an inch in the foot- inch nomenclature or to the nearest millimeter in the SI nomenclature. Corresponding system of measurement units may also be included, expressed in the foot-inch or SI

nomenclature. Nominal floor and platform elevations shall be to the nearest 1/2 in. in

of a meter (1 centimeter) in the SI nomenclature.

the foot-inch nomenclature or 1/100

th

1.6.2 Engineering Documents

Maintain the following documents on file at Seller’s shop, and make available for review by Buyer’s representative:

a. Welder qualification records

b. Packaging and shipping (when applicable) procedures

1.7 REFERENCES

1.7.1 Referenced Codes and Standards

Comply with the latest edition, revision, or supplement of referenced codes and standards in effect on the date of contract. In all instances of conflict between this standard specification or the parent MR and referenced codes and standards, follow the most stringent and conservative requirements.

AISC

American Institute of Steel Construction

AMCA

Air Moving and Conditioning Association

ANSI

American National Standards Institute

ASME

American Society of Mechanical Engineers

ASTM International

American Society for Testing and Materials

AWS

American Welding Society

IEEE

Institute of Electrical and Electronics Engineers

ISA

Instrumentation, Systems, and Automation Society

NEC

National Electrical Code

NEMA

National Electric Manufacturer’s Association

NFPA 85

National Fire Protection Association

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Specification 3SS-MAA0-00001

OSHA

Occupational Safety and Health Administration

SSPC

Steel Structures Painting Council

1.7.2 CE Mark and Compliance with European Union Directives

a. For equipment being furnished for installation in the European Union market, provide a CE Mark and Declaration of Conformity (as applicable) to indicate compliance with the relevant Council Directives of the European Union. Give particular attention to the following directives:

Electromagnetic Compatibility – 89/336/EEC and Amendment 92/31/EEC

Low Voltage Electrical Equipment – 73/23/EEC

Machinery – 98/37/EC

Pressure Equipment (PED) – 97/23/EC

b. For machinery, include the Declaration of Conformity with the Seller’s document submittals to the Buyer.

c. For electrical equipment, retain the Declaration of Conformity and make it available to the Buyer for inspection, if required. Submission of a Declaration of Incorporation for equipment in lieu of a CE Mark and Declaration of Conformity will be permitted only with the Buyer’s prior agreement and will generally be allowed only under exceptional circumstances.

d. As a part of installation instructions for electrical equipment, include specific guidelines and advice concerning both avoidance of, and immunity to, electromagnetic disturbance.

e. Assume responsibility for selecting Notified Bodies and recognized third-party organizations needed to carry out full compliance and affix CE Mark.

2.0 PRODUCTS

2.1 MATERIALS

2.1.1 Provide material suitable for the specified service and conditions stated in the

parent MR, subject to acceptance by the Buyer. Where specific materials are identified

in the parent MR, predicate the base bid on the use of specified materials; however, alternative material of equal or superior properties may also be offered for consideration. Where specific materials are not identified, use Seller’s standard material for the specified application.

2.1.2 Provide all new material, parts, and equipment of current manufacture that are

free from defects affecting performance or appearance.

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Specification 3SS-MAA0-00001

2.1.3 Do not use asbestos or asbestos-containing materials.

2.2 DESIGN REQUIREMENTS

The Buyer reserves the right to review the Seller’s design, including documentation, design processes, and manufacturing process, and to provide open feedback and suggestions. This review may include reviews at the Seller’s facilities. The Seller shall retain full responsibility for the design, manufacture, and shop-testing of equipment, including all components and materials provided by subsellers.

2.2.1

General

a.

Furnish variable-pitch, axial fans with a horizontal axis of rotation and airfoil blade design. Design fans to be smooth running with minimum vibration during startup, shutdown, and over the entire range of the operating load.

b.

Design fans to limit maximum vibration amplitude measured from peak to peak under any operating condition to 2 mils (50 microns) in any direction for bearings and pedestals, 4 mils (100 microns) for housing, and 10 mils (250 microns) midway between housing stiffeners.

c.

Buyer will provide details of the inlet duct cross-sectional area to the Seller so that Seller can determine the velocity pressure to fit/size Seller’s fan.

d.

Structurally design fan and silencer in accordance with NFPA 85.

e.

Review the arrangement of the inlet ducting provided by the Buyer for acceptance criteria in meeting the performance parameters stated in the parent MR.

2.2.2

Capacity, Performance, and Design

a.

Design the fans in accordance with the requirements stated in the parent MR.

b.

For fans operating continuously, provide performance data as required at each of the operating points shown in the parent MR. State in Seller’s proposal the conditions or changes in the system resistance under which fan instability, stalling, or surging may become a problem.

c.

The fan static pressures are defined in AMCA Publication 801-01, Industrial Process/Power Plant Fan Specification Guidelines. Subscripts 1 and 2 refer to planes 1 and 2, respectively, which are defined as follows:

Plane 1 – Seller’s ID fan inlet box flange

Plane 2 – Seller’s ID fan outlet flange of transition duct

Fan static pressure is defined as FSP = SPO Plane2 – TPI Plane1 .

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Specification 3SS-MAA0-00001

d. Select the fan to allow for maximum efficiency possible at the maximum continuous rating (MCR) load point and provide test block conditions at maximum blade pitch.

e. Make the necessary allowances for pressure losses of components that are in Seller’s scope of supply, between planes 1 and 2 and as defined in para. 2.2.2.c.

f. Base the “as-quoted” performance of the fans on a certified fan curve that represents the results of a test conducted in accordance with AMCA Standard 210, Laboratory Methods of Testing Fans for Rating.

g. Design the fan housing and rotor materials for operation at a maximum continuous temperature of the test block rating.

h. Interpret the fan "test-block" design to mean that the fan shall meet the specified design conditions, with allowances for all included appurtenances (i.e., with inlet box losses, shaft losses, silencer losses) and including any losses due to the design and inefficiency of the fan by the fan manufacturer.

i. Design inlet box, blades, intermediate piece, diffuser, rotor materials, and flue gas velocities for a particulate loading as specified in the parent MR.

j. Design the fan so that the regulating speed for blade actuation from completely closed to completely open is a maximum of 30 seconds and so that the difference between the speed for opening and closing is insignificant. Provide only a hydraulic regulating system, with actual blade position feedback such that hysteresis does not exceed +/- 0.6 percent. Any exceptions to this requirement shall be approved by the Buyer, unless otherwise specified in the parent MR.

k. Select a fan design that never operates in the stall range and that, from the fan design load point to the stall line, has a minimum safety margin of 10 percent on test block pressure. To detect stall and to prevent the fan from operating in stall, provide stall probes for each impeller.

l. In the operational requirements, consider the startup and shutdown of one fan while the other fan(s) is (are) operating at MCR. Each ID fan will discharge flue gas through a Buyer-supplied isolation damper and into a duct common to both fans.

2.2.3 Equipment Interface

a. Furnish rectangular inlet and discharge connections with suitable structural steel flanges with smooth, flat surfaces to make gastight connections when supplied with suitable asbestos-free gaskets and bolts. Drill flanges for bolts, with bolt spacing not to exceed 10 times the thickness of the flange. Weld type flanges with only alignment bolts are also acceptable.

b. Furnish standard NPT instrument and pipe connections.

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Specification 3SS-MAA0-00001

2.2.4

Foundations and Supports

a.

Furnish heavy structural steel base flange or equivalent construction to support fan housing structure. Design the support with sufficient rigidity, through its thickness and its method of attachment to housing, to ensure an adequate bearing surface for blocks and wedges to be used in setting up and leveling the equipment and to prevent local bending when wedges are driven in.

b.

Provide a means of accessing and inspecting the internal fan bearings, airfoil blades, blade positioning linkages, hydraulic piping, lube oil piping, thermocouples, etc., without complete fan disassembly. Provide access to inspect the impellers from the upstream and downstream sides.

c.

Provide supporting devices for access and removal of the diffuser and inlet box.

2.2.5

Fan Static Parts

a.

Furnish fan housing(s) and inlet boxes of steel plate not less than 5/16 in. (8 mm) thick to preclude warping and excessive vibration over the entire operating range, from no flow to full flow. Provide inspection doors to enable visual observation of the fan hub, blades, and impeller casing. Provide doors on the intermediate section that will allow blade replacement without disassembly of inlet box or diffuser. Provide removable section so that rotor may be removed in the same level, horizontal plane. Provide inspection doors for access to inlet and outlet spaces, designed to be airtight when closed, convenient for opening and closing, and raised to accommodate insulation. Fit a clean-out door to allow easy access to the inner tube. Design housing and inlet box to prevent excessive velocities and minimize losses due to turbulence, friction, and erosion. Provide low point drains for the fan housing(s).

b.

Provide seals adjacent to the shaft or provide seal air system to seal the fan shaft from leakage where it passes through the inlet box and other points of possible leakage. Provide access to seals. Distortion of the fan housing during normal operations is not acceptable.

c.

Install required stiffening of diffuser, intermediate piece, and inlet box at the Seller’s or subsupplier’s manufacturing facility.

d.

Split the intermediate piece horizontally to allow easy access to the main bearing assembly.

e.

Provide an impeller casing that is lathe-turned on the inner surface to ensure smooth clearance between the blade and the casing. Fit an inspection cover to give access to the blades. Furnish impeller casing not less than 3/8 in. (10 mm) thick after machining.

f.

Provide a one-piece diffuser unless otherwise specified in the parent MR. To ensure high fan efficiency, provide an optimized design to recover static loss due

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Specification 3SS-MAA0-00001

to velocity increase at rotor outlet. Provide access to the inner tube through an inspection cover at the diffuser end. Provide guide vanes to straighten the flow to the diffuser.

g. Provide inspection ports at the inlet and outlet sections of each fan stage and at the upstream and downstream sides of each bearing.

h. Provide all fans with adequate test ports to support a field performance test to be carried out by others. Also, provide details for the installation of test ports in Buyer-supplied ductwork required to permit the testing of fan performance, in accordance with AMCA 803-02.

2.2.6 Impeller and Shaft

a. Fabricate component parts of the fan impeller of suitable wear-resistant material to withstand the abrasive action of fly ash loading provided in the parent MR. Provide nodular cast iron or solid alloy steel blades with a minimum lifetime of 50,000 hours of operation. Calculate the life on a basis of 10 percent wearing away of the blade chord length and in such a way that the fan can meet all operating points. The rotor, hub, major hub internal parts, and blade shall have a design life of 30 years unless otherwise specified in the parent MR.

b. Mount the blades on the blade pivot by means of a bolted connection. Fix the position of each blade by means of a bolt. The centrifugal moment and the blades shall be 100 percent balanced; blade centrifugal moment shall not affect regulating parts. If, by accident, the regulating unit fails, the blades shall remain in the last position set.

c. Design the fan for complete replacement of blades within 8 hours, without removing the hub.

d. Regulate the blades by means of a hydraulic system consisting of a hydraulic cylinder, regulating arm, hydraulic lube oil supply unit, and electromechanical actuator. In a preset hydraulic pressure system, the blade control cylinder shall be activated by varying the oil flow.

e. Enable the fan blade angle to be hydraulically controllable during operation by means of a central unit. Design the fan to be fully controllable down to 15 percent load. To avoid exposing the blade bearings to excessive wear, provide fan regulation that achieves only the required regulation but does not allow the blade angle to hunt.

f. Design the fan so that all natural frequencies originating from the combined system rotating and static parts, including the fan motor, do not disturb the smooth running of the fan.

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Specification 3SS-MAA0-00001

The torsion natural frequencies of the combined fan and the motor shaft system shall be at least 15 percent away from any multiples of fan operational speed.

The First Critical Speed, as defined in AMCA Publication 801-01, of the combined fan motor shaft system shall be at least 60 percent above the fan operational speed.

The First Resonant Speed, as defined in AMCA Publication 801-01 and applicable for rigid supports, of the combined system of rotating parts (such as rotor and impeller) and stationary parts (such as bearing housing, bearing supports, and, for sleeve bearings, the bearing oil film) shall be at least 30 percent above the fan operational speed.

To ensure smooth running, resonant speeds shall be well away from any multiple of fan operational speed.

g. Design the fan so that blade replacement is possible through an inspection cover in the impeller casing and so that overhauls can be done without dismantling the fan casing.

h. Provide a shaft made of forged high-grade steel. Thermally stress relieve and ultrasonically test the shaft.

2.2.7 Bearings

a. For the main bearing assembly, provide roller and ball bearings or, alternatively, sleeve bearings, with a forced lubrication system. Include a locating bearing and

a floating bearing to allow extension/contraction of the shaft due to temperature

variation. If sleeve bearings are selected, provide the details for handling radial and thrust loads.

b. Furnish radial bearings and thrust bearings with a minimum L-10 lifetime of 100,000 hours and 70,000 hours, respectively. Subject the main bearing assembly to a fully instrumented full-speed, full-load running test with the rotating elements for 8–12 hours before delivery.

c. Furnish a complete Bentley Nevada, or approved equal, seismic vibration

monitoring system in a weatherproof housing with power supplies, monitors, and one velometer point per bearing. Provide a 4-20 mA dc output from each measurement. Furnish an independent monitoring system for each fan. Provide

a NEMA 4X junction box for transducer termination strips, with monitors remotely located in NEMA 12 cabinets.

d. Prepare the fan for installation on a concrete foundation provided by the Buyer. Provide anchor bolt requirements, bolt material, diameter, length, and configuration.

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Specification 3SS-MAA0-00001

e. Furnish thrust bearings for airfoil blades.

2.2.8 Lubrication

a. Provide lubrication for fan and motor bearings suitable for service and temperatures to be encountered. The hub may be self-lubricated or forced lubricated. The blade bearing shall be grease or sump-oil-bath lubricated. During run-up and coast-down, the system and design shall be capable of providing sufficient lubrication to the remaining movable hub parts.

b. For the main bearing assembly, provide antifriction bearings that employ a forced lubrication system. Provide adequate bearing-oil reservoirs to provide sufficient lubrication during fan coast-down if forced lubrication is lost.

c. For sleeve bearing designs, provide a forced lubrication system. Include a locating bearing and a floating bearing to allow extension/contraction of the shaft due to temperature variations. Provide a spherically seated steel body for the radial sleeves and tilting pads for axial thrust. Sufficient lubrication shall be available to maintain the oil film at low speeds during fan coastdown.

d. Provide the lube oil supply unit with two identical oil pumps, filters, and water- cooled oil coolers (one for service and the other for standby duty), complete with an oil reservoir, heating elements, valves, full instrumentation, etc. Before the assembly, grit-blast and paint oil reservoirs to make them thoroughly clean and free from foreign matter. Grit-blasting and painting shall not be required for oil reservoirs made from stainless steel.

e. If the motor requires forced lubrication, the design shall incorporate the use of the fan lube oil system.

f. Design the lubrication system to serve both the fan and associated motor drive (if required) and furnish it complete with the following, as a minimum:

Oil reservoir with a capacity equal to 10 minutes of the pump rating, as a minimum

Two motor-driven pumps (one pump to serve as the main pump and one to serve as a standby that shall activate upon loss of pressure in the discharge line)

Water-cooled oil cooler

Duplex oil filter (1.6 mil [40 micron] minimum) capable of being serviced while the fan is operating

Reservoir immersion heater with sufficient heating capacity to meet the minimum outside temperature stated in the parent MR, complete with thermostat and capable of being serviced without draining the reservoir.

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Specification 3SS-MAA0-00001

Oil level indicator

Sump drain

Pump discharge pressure and temperature gauges

Two pressure switches (one to activate the standby pump and one for the Buyer’s use)

2.2.9 Control Oil

a. Design the control oil flow to be adjustable to modify blade closure time.

b. Provide a control oil unit to supply the required oil flow for the hydraulic cylinder, complete with the following, as a minimum:

Oil reservoir with a capacity equal to 10 minutes of the pump rating, as a minimum

Two identical motor-driven pumps (one pump to serve as the main pump and one to serve as a standby that shall activate upon loss of pressure in the discharge line)

Water-cooled oil cooler

Duplex oil filter (1.6 mil [40 micron] minimum) capable of being serviced while fan is operating

Reservoir immersion heater with sufficient heating capacity to meet the minimum outside temperature stated in the parent MR, complete with thermostat and capable of being serviced without draining the reservoir

Oil level indicator

Sump drain

Pump discharge pressure and temperature gauges

Two flow switches (one to activate the standby pump and one for the Buyer’s use)

c. Furnish a fail-in-place hydraulic control drive to modulate the blade position, in compliance with NAPA-85 requirements.

2.2.10 Outlet Dampers

a. Provide isolation dampers at the gas outlet of the transition piece of each ID fan, if more than one fan is in continuous service.

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Specification 3SS-MAA0-00001

b. Provide louver-type dampers arranged to be positioned fully open or fully shut by motor operation and complete with end position limit switches.

c. Design the damper for all ID fan operating conditions, such as flue gas temperature and pressure, including permissible leakage, as specified in the parent MR.

d. Provide all dampers with electric motor drivers sized for the duty and operating conditions specified in para. 2.2.10.c. Make drive components permanently accessible for maintenance during plant operation. Also provide dampers with manual operation capability in case of motor or remote operation issues.

e. Locate all damper bearings outside the damper frame separate from the shaft seals and accessible for maintenance requirements. Provide bearings with seals for dust prevention. Pipe any grease fitting required for damper lubrication to an area accessible by the permanent walkways or platforms.

f. Design blade and frame seals to be replaceable, insensitive to solid accumulations, and of corrosion-resistant material for the flue gas composition and temperature specified in the parent MR.

g. Design all penetrations through and attachments to the damper frames to prevent leakage of gas and/or air.

h. Shop-mount damper drive, limit switches, and other components on the damper, permanently wired in conduit, and made an integral part of the damper before shipment.

i. Material selection, and construction of seals shall take into consideration the dimensional changes due to temperature variations caused by the flue gas conditions. Design blade seals for easy installation, removal, and replacement.

j. Provide blade with a deflection less than 1/360 of blade span. Stress on each blade assembly, based on system design static pressure differential, temperature, and seismic loading determined by the moment of inertia through the cross-section of the blade assembly, shall not exceed those levels specified in the AISC Manual.

2.2.11 Instrumentation and Controls

a. Furnish each fan bearing with a dual-element, ISA Type E, Chromel-Constantan, spring-loaded, grounded junction thermocouple, complete with well and weatherproof head.

b. Embed thermocouple sheath in bearing material. Locate weatherproof heads to facilitate maintenance while fans are in service.

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Specification 3SS-MAA0-00001

c. Provide sufficient instrumentation to monitor fan and hydraulic systems for proper operation. As a minimum, the following parameters shall be monitored to ensure proper operation:

Bearing temperature

Bearing vibration

Servomotor actuator torque

Motor operation

Fail-in-place blade pitch control system on loss of hydraulic pressure, with alarm to DCS

Hydraulic system pressure, temperature, and level

Lubricating system pressure, temperature, and level

Seal air pressure

Stall detection system, complete with probes, transducers, and alarms

2.2.12 Flexible Couplings and Coupling Guards

a. Furnish each fan with flexible-gear or double-flexible steel disc-pack couplings with all-metal construction and steel body with angular and axial flexibility sufficient to allow for thermal expansion and other movements of fan stator and shaft as well as motor stator, including the shaft. Select couplings to transmit, with an appropriate margin, the maximum torque that can be developed under all starting and operating conditions.

b. Machine finish and balance motor half couplings to the motor manufacturer’s specifications and coordinate this information with the motor manufacturer. Ship motor half couplings, together with the Seller’s recommended dimensions and mounting instructions, to the motor manufacturer for mounting. Identify both halves of each coupling to ensure reassembly of the correct pair. If fan components can be field erected with the fan half coupling in place, mount the half coupling in place before shipment. If the fan half couplings cannot be shop mounted, ship them loose with the fan.

c. Furnish coupling guards and other necessary guards to eliminate safety hazards and to comply with the requirements of OSHA, local regulations, and other jurisdictions at the jobsite. Furnish coupling guards that totally enclose the couplings and shafts, extending from bearing to bearing if outside of the inlet box. Split each coupling guard along the horizontal centerline, so that the top half can be removed without disturbing the lower half.

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Specification 3SS-MAA0-00001

2.2.13

Seal Air System

a.

Provide a seal air system to cool and prevent flue gas from entering the hub of fan rotating parts (other than fan blades), inlet box inner tube, intermediate piece, and diffuser center housing.

b.

Provide the seal air system complete with necessary pressure detectors, pressure indicators, ductwork, filters, silencers, and expansion joints. Seal air blowers shall be controlled from a Seller-supplied central control panel.

2.2.14

Expansion Joints

a.

Expansion joints at the inlet box and at the outlet of the fan discharge chamber shall be Corten or equal steel of sufficient thickness. Flexible parts shall be made from material suitable for the flue gas conditions as specified in the parent MR.

b.

Provide expansion joints of 1/8-inch (3 mm) minimum thickness suitable for the flue gas conditions, including acidic conditions and ammonia slip, that are capable of withstanding any upset conditions as specified in the parent MR. Design expansion joints with interior baffles to prevent ash accumulation, if specified.

c.

Expansion joints shall be suitable for service where frequent boiler startups will not lead to failure due to acid attack. Furnish the expansion joints complete with angle, interior seal plates, and exterior hoods for rain protection. Fabricate expansion joints in one piece or the largest pieces subject to shipping constraints, so that field erection time is minimized.

2.3 MOTOR DRIVES

Furnish motor(s) in accordance with the parent MR. Furnish outlet damper motor drives in accordance with the parent MR.

2.4 NOISE LEVELS

2.4.1 Fan and Drive

Provide acoustic insulation to limit noise emissions from the ID fan casings to a sound pressure as specified in the parent MR. These levels are applicable under free-field sound propagation conditions and are exclusive of any extraneous background noise from other plant sources.

2.4.2 Silencers (if required)

a. Design the silencer outlet noise performance to meet the following dynamic insertion loss requirements:

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Specification 3SS-MAA0-00001

31.5

63

125

250

500

1k

2k

4k

8k

(Hz)

5

9

20

31

22

15

12

9

4

(dB)

b. These requirements are preliminary, with project-specific requirements currently being developed. Design the silencers for these criteria, as a minimum, and be capable of providing a silencer that meets all reasonable noise emissions.

c. Design silencers to limit internal gas velocity to 5,000 fpm (25 m/s).

d. Design silencers to limit flange-to-flange pressure loss to 1.0 in. (25 mm) w.g.

e. Construct silencers of Corten or equal steel of sufficient thickness to provide structural strength for the maximum flow and to provide sufficient corrosion allowance for a projected 30-year life. Provide casing plate steel of 3/8 in. (10 mm) minimum thickness.

f. Provide reactive-type silencers.

2.5 FABRICATION

2.5.1

Welding

a.

Perform and document all welding in accordance with applicable U.S. standards.

b.

Perform all preheat, welding, and heat treatment in accordance with the applicable AWS D1.1 for casing and AWS D14.6 for rotating components. Qualify welding procedures in accordance with the applicable code. Welding done to AWS D1.1 may be performed with a prequalified procedure, where allowed.

c.

Coat final weld-end preparations for carbon steel pipe, structural/miscellaneous steel, plate, etc., with a weldable primer (Bloxide or approved equal). Weldable primers containing zinc are not acceptable for steel that attaches to austenitic stainless steel. Extend the coating at least 3 in. (75 mm) from the prepared end.

2.5.2

Stress Relieving

a.

Before stress relieving, machine or grind the rotor to eliminate stress risers at the inlet and periphery of the wheel due to fabrication and handling procedures.

b.

Stress relieve wheels after fabrication in accordance with AWS D14.6.

c.

After stress relieving, test welds in the rotor by magnetic-particle or liquid- penetrant inspection, to ensure that no cracking has occurred during the stress relieving process.

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Specification 3SS-MAA0-00001

2.5.3 Cleaning and Painting

Provide surface preparation, painting, and cleaning in accordance with the parent MR.

2.5.4 Nameplates

Provide each axial ID fan with a permanent, corrosion-resistant nameplate showing the purchase order number, Buyer’s equipment tag number, equipment serial number, and service conditions. Refer to the Technical Specification for General Project Requirements (see parent MR) for additional requirements. Locate the nameplate so that it is completely visible after equipment installation.

2.5.5 Preassembly

Before shipment, preassemble all components being furnished under this specification to the maximum extent possible, considering the selected means and route of transportation to the jobsite. Avoid the use of “escort” loads, if possible.

3.0

EXECUTION

3.1

INSPECTION

3.1.1

Inspect and test all materials and work pursuant to the purchase order.

3.1.2

Nondestructive Examinations

 

a.

After stress relieving each fan rotor weld, examine it by magnetic-particle and/or liquid penetrant methods, using procedures complying with ASME B&PV Code Section V.

b.

Use only acceptance criteria for magnetic-particle or liquid-penetrant examination that are in accordance with ASME B&PV Code Section VIII, Div. 1, Appendices 6 and 8, respectively.

c.

If cast iron or cast steel blades are provided, conduct RT examination of the sample blades from the foundry before machining in accordance with ASME B&PV Code Section V.

d.

Employ the yoke method of magnetic-particle examination for auxiliary surface examination only (e.g., detection of arc strikes and inspection of as-machined surfaces).

e.

Ultrasonically test the fan shaft in accordance with ASTM A388. The acceptance criterion for straight beam UT examination shall be not more than 25 percent loss of back reflection.

f.

Radiograph any full penetration welds on the rotor welds in accordance with ASME B&PV Code Section V. Use only acceptance criteria for RT examinations

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Specification 3SS-MAA0-00001

that are in accordance with ASME B&PV Code Section VIII, Div. 1, Para. UW-51, unless the manufacturer’s fracture mechanics (F-M) analysis indicates that larger subsurface flaws are acceptable. If the manufacturer proposes alternative RT acceptance criteria, submit such an F-M analysis for Buyer’s review. No cracks are permitted in any case.

3.2 SHOP TESTING

3.2.1 Perform a natural frequency test of the assembled (hub and blades) rotating

element. The natural frequencies measured shall be well away from at least the four multiples of the fan operational speed.

3.2.2 Statically and dynamically balance fan rotor assembly, hub, and shaft, at the

Seller’s shop. Limit residual unbalance in accordance with the criteria specified in ANSI S2.19 (ISO Standard 1940) to a balance quality of 1.8. The intermediate shaft, if any, shall also be statically and dynamically balanced. Before delivery, subject the main rotor

assembly (hub and blades) to a full-speed test that is 12 hours in duration. This test shall continuously cycle the hydraulic blade control mechanism through its full operating range.

3.2.3 Statically and dynamically balance the hub and blades separately, so that any set

of blades will fit any hub without rebalancing.

3.2.4 The hydraulic cylinder shall be tested for maximum force and speed in both

directions and shall be free from any oil leakages and operating properly.

3.2.5 Shop-assemble each outlet damper with the motor and drive links, including the

limit switches, before final inspection and testing.

3.3 SHIPPING, HANDLING, AND STORAGE

3.3.1 Set the rotor with main bearing in a cradle, with the bearing journal resting firmly

on the base of the cradle.

3.3.2 Crate or skid the blades, soleplates, and dampers. Box or crate small

miscellaneous parts and hardware.

3.3.3 If the outlet damper and its components need disassembly for shipping

requirements, match-mark the parts.

3.4 ACCEPTANCE TEST

After installation, the Buyer reserves the right to demonstrate the ability of the axial ID fan to meet the vibration limits indicating satisfactory performance outlined in ISO-3945-1977.

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